Quality Control

Quality Starts Before the Transformer Is Wound

Transformer quality is influenced by every stage of manufacturing.

For high-frequency magnetic components, consistency in materials, winding construction, assembly and testing is critical to maintaining repeatable electrical performance.

HY MFG uses a process-based quality approach covering:

Materials → Manufacturing → Inspection → Testing → Final Release

Incoming Material Control

Depending on project requirements, incoming materials may be controlled against approved specifications.

Typical materials include:

• Ferrite cores
• Bobbins
• Copper wire
• Insulation materials
• Terminals
• Sleeving
• Encapsulation materials

The objective is to ensure production starts with approved materials.

Process Control

Critical manufacturing parameters are controlled according to the approved design.

Examples include:

• Turns count
• Winding direction
• Wire specification
• Insulation construction
• Core assembly
• Air gap where applicable
• Soldering
• Potting
• Final assembly

In-Process Inspection

Inspection can be performed at defined stages to identify problems before final testing.

Depending on the product:

• Visual inspection
• Dimensional inspection
• Winding inspection
• Assembly inspection
• Insulation inspection
• Lead / terminal inspection

Final Electrical Inspection

Final inspection may include:

• Inductance
• Turns ratio
• DCR
• Hi-Pot
• Insulation resistance
• No-load current
• Other customer-defined parameters

Acceptance limits are established from the approved product specification.

Production Consistency

For OEM customers, consistency between batches is often as important as the performance of the first sample.

HY MFG focuses on maintaining consistency through:

Approved Design

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Controlled BOM

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Manufacturing Instructions

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Inspection Standards

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Electrical Testing

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Final Release

Quality for OEM Programs

For a new customer project, quality requirements can be defined during engineering and sample development rather than added after production begins.

This allows:

• Critical characteristics to be identified early
• Inspection requirements to be documented
• Test parameters to be established
• Production references to be created

Looking for a reliable high-frequency transformer manufacturing partner?

Request a Manufacturing Review